Decorative panel with finished edges

ABSTRACT

A decorative panel for vehicle interiors and the like having covered, finished edges and corners and a method for making same. A flexible cover sheet is adhered to foldable edges of a relatively stiff backing layer with a dielectrically sealable padding layer interposed therebetween. The foldable edges are folded against and secured to the back of the panel thereby stretching the cover around the resulting finished panel edges. The folded edges also overlap and help secure the previously folded corners of the cover sheet which are also adhered to the panel back. A decorative pattern which may be dielectrically sealed in the front of the panel simultaneously with the sealing of the cover to the foldable edges.

[451 Dec. 24, 1974 DECORATIVE PANEL WITH FINISHED lElDGlES [75] Inventor:

[73] Assignee: Sackner Products, llnc., Grand Rapids, Mich.

22 Filed: Jan. 12, 1973 21 Appl.No.:323,141

Jerry M. Markley, Wyoming, Mich.

[56] References Cited UNITED STATES PATENTS 2,621,142 12/1952 Wetherell 156/216 X 2,722,366 11/1955 Carlson 156/212 X 2,991,216 7/1961 Hsu et al... 161/DIG. 3 3,052,587 9/1962 Spieles 161/DIG. 3 3,075,862 1/1963 Hoyer 161/43 3,107,190 10/1963 Kevelin 161/D1G. 3

3,244,571 4/1966 Weisman l6l/DlG. 3 3,354,020 11/1967 Copeland... 161/53 3,368,692 2/1968 Voller 156/257 X 3,400,040 9/1968 Osgood 161/104 3,446,685 5/1969 Goldstone et 211 161/119 X Primary Examiner-Harold Ansher Assistant Examiner-Henry F. Epstein Attorney, Agent, or FirmPrice, Heneveld, Huizing & Cooper [57] ABSTRACT A decorative panel for vehicle interiors and the like having covered, finished edges and corners and a method for making same. A flexible cover sheet is adhered to foldable edges of a relatively stiff backing layer with a dielectrically sealable padding layer interposed therebetween. The foldable edges are folded against and secured to the back of the panel thereby stretching the cover around the resulting finished panel edges. The folded edges also overlap and help secure the previously folded corners of the cover sheet which are also adhered to the panel back. A decora tive pattern which may be dielectrically sealed in the front of the panel simultaneously with the sealing of the cover to the foldable edges.

13 Claims, 9 Drawing Figures PATENTEI] DEC 2 4 I974 SHEET 10F 2 DECORATIVE PANEL WITH FINISHED EDGES This invention relates to decorative panels for the interiors of automobiles, trucks, mobile homes, and the like, and more particularly, to decorative panels including a covering of flexible materials wherein the panel edges and corners are covered and finished by securing the flexible material to the back of the panel in a unique manner.

BACKGROUND OF THE INVENTION Decorative panels, including those having a covering of vinyl plastic and other flexible materials, are widely known. Typically, such decorative panels have included a relatively stiff backing board over which the vinyl or other covering is manually wrapped and secured to the back thereof. Such prior known decorative panels are often difficult and time consuming to manufacture due to the hand or manual operations required in the process. Thus, the vinyl or other covering sheet must be exactly mitered or cut, especially at its corners, prior to the installation on the backing board. Then the covering must be precisely positioned on the backing after which the protruding edges of the covering are laboriously hand wrapped over the corners and edges of the backing and secured to the back surface thereof. This process has often resulted in the prior decorative panels having poorly finished corners and wavy, uneven edges due in part to both the elasticity of the vinyl covering and the fact that the adhesive securing the covering edges to the back of the backing board is often not carefully applied. Consequently, the prior methods often produced open corners wherein the vinyl or other covering pulled loose from the back of the backing board and puckered open thereby exposing the raw edges of the loosened covering. The open corner result was often compounded by the fact that the covering material was not exactly cut and positioned on the backing board. Moreover, the prior panels required the use of relatively expensive, extremely high strength adhesives, such as hot melt" polyethylene base adhesives, at certain joints since it was necessary for those adhesives to directly withstand the tensile forces present in the covering materials wrapped around the panel edges.

Therefore, the prior decorative panels produced via the prior known methods for finishing corners and edges thereon generally resulted in decorative panels which were undesirable from one or more of the above standpoints.

SUMMARY OF THE INVENTION Accordingly, it is an object and purpose of the present invention to provide a decorative panel having uniformly finished corners and edges wherein the edges of the covering material are adequately and securely fastened to the back of the panel in a quick and convenient manner. The decorative panel embodying the present invention provides significantly improved finished edges and corners since the edges and corners are securely adhered to the panel backing in a manner that prevents the edges and corners from puckering, loosening or otherwise opening to expose the raw edges of the flexible covering.

Further, it is another purpose to provide a unique method for fastening the edges of the flexible covering to the back of the panel such that the edges and corners of the flexible covering are securely retained thereon without objectionable bulkiness, puckering or uneveness.

in view of these objects and purposes, the invention provides a decorative panel with finished edges and corners comprising in combination a relatively stiff backing support layer, a layer of padding and a covering sheet of flexible material. In the preferred embodiment, the covering sheet extends over the truncated corners of the stiff backing support. layer with a dielectrically scalable padding layer being interposed therebetween. The extending portions of the covering layer are folded over the truncated corners and are secured to the back surface. Further, the edges of the covering layer are secured via suitable adhesives to the front surface of the backing layer just interior of the peripheral edge thereof. In one aspect of the invention, these covering layer edges may be dielectrically sealed along the edges of the backing layer simultaneously with the dielectric embossment of a selected decorative pattern in the covering sheet and dielectrically sealable padding layer.

Following the sealing of the covering layer edges to the backing layer and the folding of the extending portions of the covering layer over the truncated corners, the periphery of the backing support is folded against the back thereof along previously scored, or otherwise formed, fold guidelines outlining the periphery of the padding layer. The folding of these periph eral edges stretches the covering layer around the edge defined by the fold guidelines thereby forming a finished edge which is rounded and filled out by the padding layer. The folded periphery is thereafter secured to the back of the backing support to complete the assembly.

When assembled and completed, the folded edges of the backing layer also overlap the previously folded and secured extending corner portions of the cover sheet at the corners of the decorative panel thereby forming a smoothly folded, finished corner which is doubly secured to the panel back. This double reten tion comprises both the primary securing of the cover sheet to the back of the backing layer via suitable adhesive in addition to the overlapping engagement of the folded peripheries of the backing layer.

Consequently, the resulting decorative panel includes finished corners which include little or no pucker, are securely adhered to the back surface of the backing layer and are prevented from loosening or opening because of the overlapping nature of the bendable, peripheral flaps. Further, the covered edges of the decorative panel are uniform and include little or no uneveness since the covering material is folded and stretched over the fold lines defined by the scoring on the front surface of the backing layer and adhered securely to the back surface of the backing layer via the folded flaps.

Moreover, the padding layer provides the panel with a luxuriant, resilient depth adding to the aesthetic appeal of the finished panel. Additionally, the padding layer fills out and provides roundness for the folded edges and corners of the resultant panel. Further, since it is preferable that the backing layer be formed from corrugated or other cardboard, an adhesive suitable for bonding paper to paper is used in securing the peripheral flaps to the back surface of the backing layer. Such an adhesive is generally less expensive than other previously used adhesives.

Additionally, another advantage of the present inven tion is that it provides a decorative panel with covered and finished edges and corners while obviating the need to exactly miter or cut the edges and corners of the covering material prior to installation on the panel. Thus, the covering layer need not be precisely positioned on the backing layer, but need only be positioned such that portions thereof extend beyond the diagonal edges of the truncated corners provided on the backing layer. While other portions extend over the fold guidelines for adherence to the foldable flaps. If only these two dimensional requirements are met, the present method allows the production of uniformly covered edges and corners without attention to dimen sional detail.

These and other objects, advantages, purposes and features of the invention will become apparent from a study of the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a decorative panel of the present invention shown in a typical installation on the interior of an automobile door;

FIG. 2 is a perspective view of the decorative panel of FIG. 1 showing the rounded, uniform corners and edges obtained via the present invention;

FIG. 3 is a broken, back, plan view of the decorative panel of FIGS. 1 and 2 showing the configuration of the backing layer and covering sheet in phantom prior to folding as well as the finished corners and edges;

FIG. 4 is a broken, cross-sectional view of the decorative panel taken along plane IV-IV of FIG. 3;

FIG. 5 is a perspective view of the backing support layer included in the present invention with the bend able, peripheral flaps shown partially folded in phantom;

FIG. 6 is an exploded, perspective view of the several parts of the decorative panel of the present invention shown prior to assembly;

FIG. 7 is a perspective view of a partially assembled decorative panel after the adhering of the flexible covering layer to the backing layer and prior to the folding of the extending portions of the covering layer and the folding of the bendable peripheral flaps;

FIG. 8 is an enlarged, fragmentary, perspective view of the back surface of one corner of a partially assembled decorative panel; and

FIG. 9 is an enlarged, fragmentary, perspective view of one corner of a completed decorative panel showing an extended portion of the covering layer folded and secured beneath the bendable, peripheral flaps on the back surface of the backing layer.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings in greater detail, FIG. 1 illustrates a decorative panel 10 embodying the present invention shown secured in a typical installation as an interior panel on the interior of an automobile door 11. Generally, such panels may also be used in various decorative installations and application such as in mo bile homes, motor homes, trucks, buses, yachts, and indeed all installations where a fabric or vinylcovered panel is desired for decorative purposes. As shown in FIG. 2, the panel 10 includes finished corners l2 and edges 14. Both the corners 12 and edges 14 are uniformly covered with a flexible covering sheet 40 as will be described more fully below. The panel may include various decorative embossed patterns 55 for enhancing the appearance thereof.

As is best shown in FIGS. 4 and 5-7, each decorative panel 10, in the preferred embodiment, comprises three elements including a backing support layer 20, a covering sheet or layer of flexible material, and a pad ding layer 50 interposed between the backing layer 20 and covering layer 40. Preferably, the backing layer 20 is a sheet of corrugated cardboard as shown in FIG. 4. Other relatively stiff solid cardboard or fiberboard sheets and the like may also be used. The covering sheet of flexible material 410 preferably comprises a dielectrically scalable vinyl plastic, vinyl impregnated cloth or another similarly durable, flexible material. The padding layer 50 may be any type of fibrous or foamed padding layer but preferably comprises a fusible, polymeric, foam fibrous pad of the type described in US. Pat. No. 3,354,020, issued to Richard S. Copeland, and assigned to the same assignee as the present invention, the disclosure of which is incorporated by reference herein. Although various other types of padding layers are acceptable, the foam fibrous pad described in the Copeland patent provides desirable dielectric and resilient qualities adding to the overall aesthetic and structural advantages of the present decorative panel. Although the padding layer is included in the preferred embodiment, decorative panels using the present novel edge and corner forming concepts may be made without intermediate padding layers.

The basic concept of the present invention resides in th provision of finished edges and corners for the decorative panel 10 via a unique method of securing the covering sheet or layer 40 over the padding layer 50 and around the peripheral edges of the panel 10 to the backing support layer 20. Foldable edges on the backing support, with the covering sheet edges attached thereto, are folded back and secured against the back surface of the decorative panel 10. The folded backing support edges clamp the previously folded, extending corner portions of the covering sheet 40 against the back surface of the backing support layer. In addition, the method of fastening the covering sheet edges to the backing support is secure since those edges are first adhered to the foldable peripheral flaps of the backing layer ad thereafter portions of those edges are clamped between the folded flaps and the backing support. This provides a double assurance against the release of the covering sheet edges. Thus, a panel is provided having finished corners and uniformly straight, even, finished edges both of which are securely retained and prevented from loosening. Moreover, the finished edges and corners are manufactured via a method which is quicker, more convenient and much easier to perform than the previously known covering methods.

In reference to FIGS. 3, 4, and 5, the backing support layer 20 includes a front, generally planar surface 22 as well as a back, generally planar surface 24. These surfaces are parallel and correspond to the outer surfaces of the corrugated cardboard mentioned above. In the preferred embodiment, these surfaces will be spaced apart by a corrugated inner member 26 (FIG. 4). However, when other types of cardboard are utilized, the inner area of the backing layer 20 between surfaces 22 and 24 may be solid, honeycombed, etc. The backing layer includes peripheral edges 28 and truncated corners forming diagonal edges 32 extending between the peripheral edges 28. The truncated corners are formed merely by removing the apexes of any corners. Preferably, the diagonal edges 32 formed by the truncated corners 30 are formed such that the angles between the diagonal edge and each of the peripheral edges which it joins are equal. These angles are represented by A and B in FIG. 3.

The edges of the finished panel 10 are formed via fold guidelines 34 which are scored or cut in the front surface 22 of backing layer 20. Scored lines 34 thereby divide the backing layer 20 into bendable, peripheral flaps 36 and a central backing support area 38. Preferably, the lines 34- are scored or out only partially through the thickness of the backing layer 20. Thus, in the preferred embodiment using corrugated cardboard, guidelines 34 are cut or scored through only the outer surface 22 and the corrugated inner member 26. The remaining outer surface 24 is thereby left intact and serves as a hinge for folding flaps 36. Consequently, the bendable, peripheral flaps 36 may be bent or folded backwards through 180 from their original positions against the back surface 24 of backing layer 20.

The scored lines 34 extend between points 33 (FIGS. 3 and 8) on the diagonal edges 32 along and adjacent to the peripheral edges 28. In the preferred embodi ment, points 33 are spaced slightly apart a small dis tance represented by D in FIGS. 3, 8, and 9 thereby forming an intermediate area 35 on edge 32. Points 33 are located along the diagonal edges approximately midway between the two peripheral edges joined by each of those diagonal edges. The slight spacing D between points 33 provides a slight spacing between the folded flaps 36 when secured to back surface 24 as shown in FIG. 9. The central location of points 33 on diagonal edges 32 provides approximately equivalent widths for all of the flaps 36 around the entire periphery of the central backing support area 38.

Referring now to FIGS. 3, 6, and 7, the covering sheet or layer 40 comprises a piece of flexible material of the type described above having a geometrical shape corresponding to that of the backing layer 20 but having slightly smaller, overall dimensions. The sheet cover 40 has sufficient dielectrically sealable qualities such that it may be dielectrically sealed to said padding layer in preselected patterns. In the preferred embodiment, the backing support layer 20, as well as the covering layer 40 and padding layer 50, are rectangular. However, it will be understood that the decorative panels 10 and elements thereof may be made in any geometrical shape. Covering sheet 40 includes extending portions or corners 42 which extend beyond the diagonal edges 32 of truncated corners 30. Portions 42 need not be triangular in shape as they are shown in FIG. 3, but may have any sufficient material shape as long as sufficient provided to fold over edge 32 and cover the area 35 of edge 32 between points 33. Generally, the dimensions of the covering sheet 40 are sufficient to allow the edges 44 of the covering sheet to partially cover the bendable flaps 36 as shown in FIG. 7. Thus, the covering sheet 40 extends past the scored lines 34, over the peripheral flaps 36 and is secured thereto with a suitable adhesive. As will be explained more fully below, this adhesive is of the type which is suitable for securing vinyl plastic, vinyl impregnated cloth, or other fabrics or synthetics to paper or cardboard.

As shown in FIG. 6, the intermediate padding layer 50, which is included in the preferred embodiment, has a geometric shape corresponding to the outline of the finished panel, i.e., the outline formed by the scored lines 34. Therefore, the padding layer will extend within the entirety of the complete, finished decorative panel 10 and provides sufficient padding to fill and round out the finished edges and corners of the panel 10.

The adhesive used to adhere the peripheral edges 44 of cover sheet 40 to peripheral flaps 36 is preferably any dielectrically activatable adhesive such as those in the group including polyvinyl acetate, polyvinyl chlo ride or any of several acrylic adhesives. The adhesive used to secure extending corners 42 to back surface 24 may also be such a dielectrically actuatable adhesive but is preferably a water base, contact cement. The adhesive used to adhere the peripheral flaps 36 to back surface 24 is preferably also water base, contact cement. Of course, if the dielectrically activatable adhesives are not used, the same adhesive, such as water base, contact cement, may be used for all joints in the panel. Thus, the water base, contact cement is suitable for adhering both vinyl or fabric to paper as well as paper to paper. This type of cement or adhesive is generally less expensive than other types of adhesives used in prior methods of securing covering sheets to backing supports such as hot melt polyethylene base adhe' sives.

DESCRIPTION OF THE METHOD Referring now to FIGS. 5 through 9, the process for making the decorative panels 10 in accordance with the present novel inventive concepts will be described in greater detail. As shown in FIG. 5, a backing support layer 20 is provided with any corners thereon being removed along a diagonal line between the two peripheral edges forming the corner. Thus, truncated corners 30 are formed having diagonal edges 32. As described above, the diagonal edges in the preferred embodiment form the same angle with each of the edges 28 (represented by equivalent angles A & H3 in FIG. 3). In the rectangular panels shown herein, these angles will, of course, be 45.

After cutting the backing layer 20 to the desired shape, fold guidelines 34 are scored on the front surface 22 of the backing layer 20. In the preferred embodiment, lines 34 are scored only partially through the corrugated cardboard backing layer 20 and are rectilinear lines extending between the points 33 located approximately midway along the diagonal edges 32 of the several truncated corners 30. The scored lines 34 form the peripheral flaps 36 and central backing support area 38, the peripheral flaps 36 being allowed to bend through via the hinge areas of back surface 24. Thus flaps 36 may be bent to lie flat against the back surface 24 of the backing layer 20. The outline of the scored lines 34 will, of course, correspond to the outline of the finished decorative panel 10.

Following the scoring of the guidelines 34 on thefront surface of the backing layer 20, an adhesive suitable for securing the flexible covering sheet 40 to the backing layer 20 is applied to portions of the front surface 22 including the front surfaces of the peripheral flaps 36. In the preferred embodiment, as described above, this adhesive will be a dielectrically activatable adhesive such as polyvinyl acetate, polyvinyl chloride, or an acrylic adhesive. Furthermore, in the preferred embodiment, this dielectrically activatable adhesive (not shown) will be applied over the entirety of the front surface 22 of the central backing support area 38 such that the covering layer 40 and padded layer 50 may be dielectrically embossed with a decorative pattern by fusing the cover 40 and pad 50 to the front surface 22 in certain areas simultaneously with the sealing of the covering sheet edges 44 to the peripheral flaps 36. It is possible to commercially obtain backing support materials such as cardboard or fiberboard already having coatings or such dielectrically activatable adhesives applied thereto. Absent such precoated backing layers, however, the adhesive may be applied as needed.

Following the application of a suitable adhesive to the front surface 22, or portions thereof, the padding layer 50 is laid within the outlines of the scored lines 34 atop the front surface 22. Next, the covering sheet or layer 40 is laid over the top of the padding layer 50 with its edges 44 resting along the peripheral flaps 36 and its extending corners 42 protruding beyond the diagonal edges 32 of truncated corner 30. In this step exact positioning is not crucial, the only requirement being that corners 42 protrude over edges 32. Following the above assembly, the edges 44 of the covering layer 40 are adhered (via dielectrically sealing in the preferred embodiment) to the peripheral flaps 36. This step is preferably done simultaneously with embossing a decorative pattern 55 in the central areas of the decorative panel as shown in FIGS. 1 and 2. In this connection, it will be understood that the padding layer 50 will be composed of a foam-fibrous pad of the type described in Copeland US. Pat. No. 3,354,020. This is a nonwoven pad which is particularly suited for dielectric embossing.

Subsequent to the sealing of edges 44 to peripheral flaps 36, the extending corners or portions 42 of covering layer 40 are tightly folded around diagonal edges 32 and adhered via a suitable adhesive to the back surface 24 of backing layer as shown in FIG. 8. As described above, the adhesive used for this operation may be a dielectrically activatable adhesive such that the extending corner 42 is dielectrically sealed to the back surface 24 but is preferably a water base, contact cement.

Thereafter, each of the bendable, peripheral flaps 36 is folded through 180 via the hinge areas of back surface 24 such that the extending corners 42 are folded and secured between the flaps 36 and the back surface 24. The flaps 36 are then adhered to the back surface 7 24 via a suitable adhesive which is preferably a water base, contact cement as described above.

As shown in FIG. 9, the respective portions of diagonal edge 32 are spaced slightly apart by a distance D and extend parallel to one another inwardly from the finished corner 12 overtop the folded extending corner 42 which lies between the flaps 36 and back surface 24. The result is a neatly and smoothly folded, finished and covered corner 12 which has no puckering and minimal bulkiness and which has little tendency to pull loose or open" and, therefore, expose the raw edges of the covering material 40 as was experienced with the prior construction methods of manufacturing decorative panels. It will be understood that the overlapping nature of the peripheral flaps 36 over the folded extending corner 42 is a major reason for preventing the opening of the finished corners. This overlapping feature is also a major factor in providing the extremely strong and secure joint between the cover sheet edges 44 and the backing layer 20. As mentioned above, edges 44 are doubly secured against loosening. They are first adhered to flaps 36. Subsequently, corner portions of the edges are clamped and engaged between the folded flaps 36 and back surface 24 of backing support 20. Thus, even if the bond between the edges and flaps should loosen, the edges will remain tightly held between flaps 36 and back surface 24 in the area finished corners 12. Consequently, this double retention or fastening effectively counteracts any tensile forces in the covering sheet which is stretched around the panel edges, and prevents those forces from loosening the finished corners and edges.

Additionally, it will be understood that the finished edges 14 of the panel 10 will be uniformly even since they follow the length of the scored lines 34 forming the fold guidelines as shown in FIGS. 2 through 4 and 9. The covering material 40 is vinyl in the preferred embodiment and, thus, includes a certain degree of integral resiliency such that the vinyl is stretched around the corner 14. This results in an aesthetically pleasing uniform edge since the vinyl is filled and rounded out by the padding layer 50 between the backing layer and covering.

Further, it will be understood that the process of assembling the decorative panel 10 in the above manner is significantly faster and more convenient since the various components need not be precisely positioned with respect to one another. Rather, the covering layer need only be positioned with its edges 44 adjacent the peripheral flaps 36 and its extending corners 42 extending beyond the diagonal edges 32. Thus, it may be skewed slightly in the assembly process without producing adverse effects in the finished decorative panel. Moreover, the corners and edges of the covering sheet 40 need not be exactly mitered or out prior to installa tion thereby allowing the flexible covering material to be machine out which reduces the overall expense and costs involved as well as the time required for the manufacturing process.

Consequently, each panel produced in accordance with the present inventive concepts will include finished corners and edges which are similar to those produced on all other panels made using the same method. Uniformity and high quality production standards are therefore assured. In addition, the overall cost of each panel is effectively reduced because of lesser production time required for each panel made with the present method as well as the relatively less expensive materials required, such as the water base, contact cement used in several of the joints of the panel.

It will be understood that the descriptive terms top, bottom, front, and back, are used merely for descriptive purposes and are not intended to limit the scope of the invention.

While one form of the invention has been shown and described, other forms will now be apparent to those skilled in the art. Therefore, it will be understood that the embodiment shown in the drawings and described above is merely for illustrative purposes, and is not intended to limit the scope of the invention which is defined by the claims as follows.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.

l. A decorative panel comprising the combination of a stiff backing layer, a pad having dielectrically scalable means incorporated therein, and a dielectrically embossable cover of flexible material; said backing having a periphery with foldable margins foldable along predetermined rectilinear lines; said pad and cover being dielectrically embossed and sealed to said backing in an area thereof along said rectilinear lines, said area of said backing being located outwardly of said rectilinear lines; said margins being folded against the back of the backing and adhered thereto whereby uniformly finished panel edges are formed with said cover extending therearound.

2. The decorative panel of claim ll wherein said backing layer is corrugated cardboard, said rectilinear lines comprising fold guidelines scored only partially through said cardboard.

3. The decorative panel of claim ll wherein said flexible covering material is vinyl plastic.

4. The decorative panel of claim 1 wherein said cover is sealed to said area of said backing with a dielectrically activatable adhesive.

5. The decorative panel of claim ll wherein said panel includes at least one folded corner, said corner com prising a portion of said cover folded over a truncated corner of said backing layer and adhered to the back thereof; said rectilinear lines extending from points along the edge of said truncated corner; said foldable margins overlapping said folded and adhered corner on said back of said backing layer whereby said folded corner is additionally secured against pulling loose.

6. A decorative panel comprising in combination a backing support and a flexible covering layer; said backing including front and back surfaces; said covering including at least one extending corner and being secured to said backing support on said front surface along the periphery thereof; said backing support including fold guidelines interior of said periphery separating said backing support into foldable margins and a central support area; said backing support further including at least one truncated corner with an edge; said extending corner being folded over said corner edge and secured to the back of said backing; said foldable margins being folded against said back of said backing and secured thereto in overlapping engagement with said extending corner whereby said cover is wrapped around the periphery of said panel forming finished, covered edges thereon and said extending corner is doubly retained and prevented from loosening.

7. The decorative panel of claim 6 wherein said fold guidelines are lines scored partially through said front surface of said backing support.

3. The decorative panel of claim 6 wherein said covering is secured to the periphery of said backing support via a dielectrically activatable adhesive.

9. The decorative panel of claim 6 wherein said fold guidelines extend between specified points on a plurality of said corner edges; said points spaced apart a predetermined distance along said comer edges; said corner edges being rectilinear.

10. The decorative panel of claim 6 wherein the outside dimensions of said covering are less than the out side dimensions of said backing support and greater than the outline formed by said fold guidelines.

ll. A decorative panel comprising in combination a backing support and a flexible covering layer; said backing including front and back surfaces; said covering including at least one extending corner and being secured to said backing support on said front surface along the periphery thereof; said backing support including fold guidelines interior of said periphery separating said backing support into foldable margins and a central support area; said backing support further including at least one truncated corner with an edge; said extending corner being folded over said corner edge and secured to the back of said backing; said foldable margins being folded against said back of said backing and secured thereto in overlapping engagement with said extending corner whereby said cover is wrapped around the periphery of said panel forming finished, covered edges thereon and said extending corner is doubly retained and prevented from loosening; said panel further including a layer of padding between said backing support and said flexible covering layer; said padding filling and rounding out said finished edges of said panel.

12. The decorative panel of claim 11 wherein said padding layer includes dielectrically scalable means; said padding and covering being dielectrically embossed in a preselected pattern.

13. A decorative panel comprising in combination a backing support and a flexible covering layer; said backing including front and back surfaces; said cover ing including at least one extending corner and being secured to said backing support on said front surface along the periphery thereof; said backing support including fold guidelines interior of said periphery separating said backing support into foldable margins and a central support area; said backing support further including at least one truncated corner with an edge; said extending corner being folded over said corner edge and secured to the back of said backing; said foldable margins being folded against said back of said backing and secured thereto in overlapping engagement with said extending corner whereby said cover is wrapped around the periphery of said panel forming finished, covered edges thereon and said extending corner is doubly retained and prevented from loosening; the outside dimensions of said covering being less than the outside dimensions of said backing support and greater than the outline formed by said fold guidelines; said panel further including a padding layer interposed between said backing support and cover; said padding layer having outside dimensions equivalent to the outline formed by said fold guidelines.

* =l l= k UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PA TENT NO. 1 3,856,611

DATED December 24 1974 |NVENTOR(S) Jerry M. Markley It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3, line 12';

After "layer", should be and "While" should be --while-; Column 4 line 35;

"th" should be -the--; Column 5, line 57;

After "any", delete "sufficient material"; Column 5, line 58;

After "sufficient", insert --material is-.

Signed and sealed this 20th day of May 1975.

(SEAL) Attest:

C. MARSHALL DANN RUTH o. MASON Commissioner of Patents Attesting Officer and Trademarks 

1. A decorative panel comprising the combination of a stiff backing layer, a pad having dielectrically sealable means incorporated therein, and a dielectrically embossable cover of flexible material; said backing having a periphery with foldable margins foldable along predetermined rectilinear lines; said pad and cover being dielectrically embossed and sealed to said backing in an area thereof along said rectilinear lines, said area of said backing being located outwardly of said rectilinear lines; said margins being folded against the back of the backing and adhered thereto whereby uniformly finished panel edges are formed with said cover extending therearound.
 1. A decorative panel comprising the combination of a stiff backing layer, a pad having dielectrically sealable means incorporated therein, and a dielectrically embossable cover of flexible material; said backing having a periphery with foldable margins foldable along predetermined rectilinear lines; said pad and cover being dielectrically embossed and sealed to said backing in an area thereof along said rectilinear lines, said area of said backing being located outwardly of said rectilinear lines; said margins being folded against the back of the backing and adhered thereto whereby uniformly finished panel edges are formed with said cover extending therearound.
 2. The decorative panel of claim 1 wherein said backing layer is corrugated cardboard, said rectilinear lines comprising fold guidelines scored only partially through said cardboard.
 3. The decorative panel of claim 1 wherein said flexible covering material is vinyl plastic.
 4. The decorative panel of claim 1 wherein said cover is sealed to said area of said backing with a dielectrically activatable adhesive.
 5. The decorative panel of claim 1 wherein said panel includes at least one folded corner, said corner comprising a portion of said cover folded over a truncated corner of said backing layer and adhered to the back thereof; said rectilinear lines extending from points along the edge of said truncated corner; said foldable margins overlapping said folded and adhered corner on said back of said backing layer whereby said folded corner is additionally secured against pulling loose.
 6. A decorative panel comprising in combination a backing support and a flexible covering layer; said backing including front and back surfaces; said covering including at least one extending corner and being secured to said backing support on said front surface along the periphery thereof; said backing support including fold guidelines interior of said periphery separating said backing support into foldable margins and a central support area; said backing support further including at least one truncated corner with an edge; said extending corner being folded over said corner edge and secured to the back of said backing; said foldable margins being folded against said back of said backing and secured thereto in overlapping engagement with said extending corner whereby said cover is wrapped around the periphery of said panel forming finished, covered edges thereon and said extending corner is doubly retained and prevented from loosening.
 7. The decorative panel of claim 6 wherein said fold guidelines are lines scored partially through said front surface of said backing support.
 8. The decorative panel of claim 6 wherein said coVering is secured to the periphery of said backing support via a dielectrically activatable adhesive.
 9. The decorative panel of claim 6 wherein said fold guidelines extend between specified points on a plurality of said corner edges; said points spaced apart a predetermined distance along said corner edges; said corner edges being rectilinear.
 10. The decorative panel of claim 6 wherein the outside dimensions of said covering are less than the outside dimensions of said backing support and greater than the outline formed by said fold guidelines.
 11. A decorative panel comprising in combination a backing support and a flexible covering layer; said backing including front and back surfaces; said covering including at least one extending corner and being secured to said backing support on said front surface along the periphery thereof; said backing support including fold guidelines interior of said periphery separating said backing support into foldable margins and a central support area; said backing support further including at least one truncated corner with an edge; said extending corner being folded over said corner edge and secured to the back of said backing; said foldable margins being folded against said back of said backing and secured thereto in overlapping engagement with said extending corner whereby said cover is wrapped around the periphery of said panel forming finished, covered edges thereon and said extending corner is doubly retained and prevented from loosening; said panel further including a layer of padding between said backing support and said flexible covering layer; said padding filling and rounding out said finished edges of said panel.
 12. The decorative panel of claim 11 wherein said padding layer includes dielectrically sealable means; said padding and covering being dielectrically embossed in a preselected pattern. 